US11246766B2 - High barrier nonwoven fabric - Google Patents

High barrier nonwoven fabric Download PDF

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US11246766B2
US11246766B2 US16/081,809 US201616081809A US11246766B2 US 11246766 B2 US11246766 B2 US 11246766B2 US 201616081809 A US201616081809 A US 201616081809A US 11246766 B2 US11246766 B2 US 11246766B2
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polymer material
nonwoven fabric
polymer
additive
melt
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US20190070045A1 (en
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Brian Udengaard
Barbara Harling Hede
Thomas Broch
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Fibertex Personal Care AS
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Fibertex Personal Care AS
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Assigned to FIBERTEX PERSONAL CARE A/S reassignment FIBERTEX PERSONAL CARE A/S ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: Hede, Barbara Harling, Broch, Thomas, UDENGAARD, BRIAN
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    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/45—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the shape
    • A61F13/47—Sanitary towels, incontinence pads or napkins
    • A61F13/475—Sanitary towels, incontinence pads or napkins characterised by edge leakage prevention means
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01D—MECHANICAL METHODS OR APPARATUS IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS
    • D01D5/00—Formation of filaments, threads, or the like
    • D01D5/28—Formation of filaments, threads, or the like while mixing different spinning solutions or melts during the spinning operation; Spinnerette packs therefor
    • D01D5/30—Conjugate filaments; Spinnerette packs therefor
    • D01D5/34—Core-skin structure; Spinnerette packs therefor
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F1/00—General methods for the manufacture of artificial filaments or the like
    • D01F1/02—Addition of substances to the spinning solution or to the melt
    • D01F1/10—Other agents for modifying properties
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins
    • D01F6/06—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins from polypropylene
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
    • D04H1/4282—Addition polymers
    • D04H1/4291—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/541—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres
    • D04H1/5412—Composite fibres, e.g. sheath-core, sea-island or side-by-side; Mixed fibres sheath-core
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/542—Adhesive fibres
    • D04H1/544—Olefin series
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/552—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving by applying solvents or auxiliary agents
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
    • D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
    • D04H1/54—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving
    • D04H1/56—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres
    • D04H1/565—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by welding together the fibres, e.g. by partially melting or dissolving in association with fibre formation, e.g. immediately following extrusion of staple fibres by melt-blowing
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/005—Synthetic yarns or filaments
    • D04H3/007—Addition polymers
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/12—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with filaments or yarns secured together by chemical or thermo-activatable bonding agents, e.g. adhesives, applied or incorporated in liquid or solid form
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/14—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic yarns or filaments produced by welding
    • D—TEXTILES; PAPER
    • D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
    • D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
    • D04H3/00—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length
    • D04H3/08—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating
    • D04H3/16—Non-woven fabrics formed wholly or mainly of yarns or like filamentary material of substantial length characterised by the method of strengthening or consolidating with bonds between thermoplastic filaments produced in association with filament formation, e.g. immediately following extrusion
    • D—TEXTILES; PAPER
    • D01—NATURAL OR MAN-MADE THREADS OR FIBRES; SPINNING
    • D01F—CHEMICAL FEATURES IN THE MANUFACTURE OF ARTIFICIAL FILAMENTS, THREADS, FIBRES, BRISTLES OR RIBBONS; APPARATUS SPECIALLY ADAPTED FOR THE MANUFACTURE OF CARBON FILAMENTS
    • D01F6/00—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof
    • D01F6/02—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
    • D01F6/04—Monocomponent artificial filaments or the like of synthetic polymers; Manufacture thereof from homopolymers obtained by reactions only involving carbon-to-carbon unsaturated bonds from polyolefins

Definitions

  • the invention relates to methods for making nonwoven fabrics comprising polymer fibers whose surface properties are modified upon including an additive to the polymer matrix.
  • the hydrophobic and oleophobic character of the fiber surface can be modified for improved barrier properties of the nonwoven, which can be desirable in the hygiene industry.
  • the invention further relates to nonwoven fabrics obtainable by such methods.
  • EP 2 270 271 B1 discloses that adding lipid esters as melt additives to the polymer matrix of the fibers leads to increased barrier properties in a nonwoven fabric.
  • EP 2 778 270 A1 describes that the increased barrier properties may be connected to a specific surface topography of the fibers, which can be obtained by including said melt additives.
  • WO 00/06817 A1 uses in-line hot air knives to increase barrier properties by additive migration in certain regions of a fabric.
  • the present invention aims to obtain improved results in surface property modification at lower melt additive concentration.
  • the invention relates to a method for making a nonwoven fabric comprising forming polymer fibers from a melt of the polymer material and using these fibers to obtain a nonwoven fabric during a subsequent nonwoven fabric formation procedure, wherein the melt of the polymer material comprises a melt additive, the method comprising thermal bonding at a temperature higher than 40° C. below the melting point of the polymer material and, additionally, one or both of the following steps to increase the relative concentration of the melt additive in the surface region of the fibers: a. improving the mobility of the additive by heat-treating the nonwoven fabric at 100° C.
  • the invention is based on the theory that fiber surface properties in general and fiber surface structure formation in particular are connected to the additive concentration at the surface. It is further based on the theory that some small molecular additives tend to travel to the surface of the fibers if allowed to migrate within the polymer matrix.
  • the steps proposed by the invention to increase the relative concentration of the additive in the surface region of the fibers correspond to two basic approaches which take account of these theoretical considerations. One of these basic approaches is to increase mobility of the polymer matrix and hence the speed the additive can migrate. The other of these basic approaches is to decrease the distance the additive has to travel to reach the surface by changing the crystallinity.
  • bonding at a temperature higher than 40° C. below the melting point of the polymer material can be carried out by calandering or hot air through bonding.
  • the polymer material consists of or comprises a thermoplastic polymer. It may consist of or comprise a polyolefin such as polypropylene and/or polyethylene and/or Ethylene-Propylene copolymer or a combination of either of these.
  • Heat treatment after the nonwoven formation procedure means that heat is applied in addition to the heat already applied as per normal production (e.g., during pre-compaction and bonding). It pertains to heat-treatment after the nonwoven has been bonded. This can be achieved by increasing the temperature in the processing of the formed nonwoven fabric (by applying one or several inline heat activation steps) and/or by post-activation when converting the nonwoven into its final application.
  • heat-treatment after the nonwoven formation procedure refers to heating the nonwoven to temperatures above 100° C., but could also refer to an increased storage temperature of the nonwoven at 30° C., 35° C. or 40° C. In some embodiments described in the following, higher temperatures are used.
  • Such heat treatment promotes the mobility of the additive and hence its migration to the surface after the nonwoven fabric has been formed.
  • the heat activation can both directly affect the movement speed of the additive as well as indirectly, by making the polymeric matrix easier to move in for the additive.
  • Heat activation already occurs during in-line thermal bonding e.g., calander bonding, through-air bonding, ultra sonic bonding and/or radiant heat bonding.
  • additional heat treatments e.g., application of a drying oven, IR radiation, hot air knives or ultra sonic heating, are applied after the nonwoven formation procedure. They can be in-line and applied to the finished and finally bonded nonwoven, but could also be off-line, or both. It could be heat treatment after the nonwoven has been cut.
  • heat activation after the nonwoven formation procedure can comprise storing the nonwoven at increased temperatures, e.g., at more than 30 or 40° C., for an extended amount of time, e.g., 12 or 24 hours or more.
  • a shorter treatment e.g., 5 seconds or 0.1 seconds or less
  • the additional heat activation of the invention, in-line and/or off-line can be in the full web area, but could also be in specific zones only.
  • heat-treating after the nonwoven fabric formation procedure includes storing the nonwoven at 30° C. or more for 12 hours or more or at 100° C. or more for 15 minutes or less.
  • fillers having a higher thermal conductivity than the polymer material are included to the polymer material.
  • Exemplary fillers include inorganic fillers such as calcium carbonate, which can have a higher thermal conductivity than the polymer matrix (e.g., than polypropylene), allowing faster and more homogeneous transfer of heat within the fiber matrix. This will allow for more benefit from the heat already applied in the processing of the nonwoven and, if any, may increase the effect of heat treatment after the nonwoven formation procedure.
  • the particle size of the filler may be important for the observed effect. In one embodiment, the average particle size of the filler is hence 10 ⁇ m or smaller, preferably 1 ⁇ m or smaller (ISO 14688).
  • the material may also be chosen to exhibit a thermal conductivity at room temperature of 1 W ⁇ m ⁇ 1 ⁇ K ⁇ 1 or greater or more, preferably 2.0 W ⁇ m ⁇ 1 ⁇ K ⁇ 1 or more (DIN EN 12664).
  • a preferred thermal conductivity could be 2.7 W ⁇ m ⁇ 1 ⁇ K ⁇ 1, which approximately corresponds to that of CaCO3.
  • the filler comprises CaCO3.
  • Suitable CaCO3 can in one example be either ground CaCO3 (GCC) or precipitated CaCO3, or a combination thereof.
  • the CaCO3 can be micro-CaCO3 (GCC) having a Plus 325 Mesh of 0.002% and/or mean particle size of 1.6 microns and/or specific surface area of 4.5 m2/g.
  • the CaCO3 can be nano-CaCO3 (PCC) having a residue on sieve 45 micron ⁇ 250 ppm and/or mean particle diameter of 0.07-0.13 microns and/or specific surface area 16 m2/g.
  • PCC nano-CaCO3
  • Such material is, for example, found under the tradename SOCAL® U1S2 from Imerys Group.
  • Step b. is concerned with changing the morphology of the polymeric matrix and hence the distance the melt additive has to navigate when traveling through the matrix.
  • a nucleating agent increases the number of sites where crystallites begin to form, thereby decreasing the area the crystallites have to grow before they will impinge on each other.
  • the crystallites will be dimensionally smaller and the additive will have a shorter distance to travel before it reaches the fiber surface.
  • melt additives are only able to migrate through the amorphous domains of the polymeric matrix at room temperature, but dependent on the degree of crystallinity (or degree of amorphousness), the geometry and size of the amorphous regions, as well as the conformation and size of the migratory additive, the additive may not be able to migrate effectively at all, as it can be too constricted to move.
  • Suitable nucleating agents can be both inorganic or organic, and insoluble and soluble in the polymer matrix.
  • the nucleating agent comprises a nonitol, trisamide and/or a sorbitol based nucleating agent.
  • Nonitol can be obtained, for example, from Millad® NXTM 8000 or any masterbatches containing that active component, e.g. NXTM UltraClear GP 110B.
  • Trisamide can be obtained, for example, from Irgaclear XT 386 or any masterbatches containing that active component.
  • a sorbitol based nucleating agent can be obtained, for example, from NC 4 from Mitsui Chemicals.
  • an inorganic particulate such as, for example, CaCO3, the inorganic particulate having a particle size of 10 ⁇ m or smaller and preferably 1 ⁇ m or smaller can be used as a nucleating agent. It has been found out that inorganic particulate can act as both nucleating agent for influencing polymer crystallinity as well as means for improving heat conduction and hence improving additive mobility. In this respect, it is observed that the improvement of heat conduction appears to be the predominant factor to influence additive migration.
  • Including branched polymers and/or random co-polymers to the polymer material may result in a polymeric matrix that inherently allows the additive to move more freely and less constricted and therefore faster. Diffusivity may be promoted, e.g., by using/adding branched polymers or random-copolymers as/to the polymer material. If branched polymers and/or random co-polymers are added to the polymer material, the indication of thermal bonding at a temperature higher than 40° C. below the melting point of the polymer material refers to the melting point of the mixture.
  • multicomponent and in particular bicomponent technology is used and the additive added to only (or predominantly) the polymer feeds eventually forming at least the predominant part of the outermost area of the fibers.
  • the bicomponent could be of core-sheath, but is not limited thereto, and can also be island-in-the-sea, side-by-side, etc. configuration allowing the additive to be added to the surface part of a given bicomponent, e.g. the sheath of the core/sheath bicomponent configuration.
  • the polymeric components of the multicomponent fiber do not have to be identical.
  • different polymers matrices are employed for the two feeds.
  • the matrix including the additive could also make use of any other measure envisioned in steps a. and b.
  • the one and the other polymer material both are made of or comprise a thermoplastic polymer, preferably a polyolefin such as polypropylene and/or polyethylene and/or Ethylene-Propylene copolymer or a combination of either of these.
  • one or more of the steps and measures mentioned may be employed.
  • heat-treating after the nonwoven fabric formation procedure and including fillers may be used in conjunction.
  • one or both of the measures for improving the mobility may be used in conjunction with either measure to influence the polymer crystallinity. This has shown to obtain very desirable effects.
  • steps and measures mentioned can be taken in conjunction with the steps and measures mentioned.
  • these other steps are spinning thinner fibers, hereby decreasing the distance from the core to the surface. This could be done, but is not limited to, increasing the MFR of the polymer and/or increasing the stress on the fibers during spinning. It is obvious to the one knowledgeable in the state of the art that the migration of a migrating additive is faster/more efficient in a thinner fiber due to the shorter distance to traverse, i.e. the speed will be higher in a fiber with a diameter of 10 micron than in one with a diameter of 20 micron.
  • the stress on fibers during spinning may also be responsible for different extents of stress induced crystallization.
  • Also among these steps are changing the morphology of the polymeric matrix by changing the heating/cooling conditions while processing.
  • the speed of cooling, super cooling is believed to be able to lock the migratory additive in the (amorphous) polymeric matrix.
  • the type of the polymer (homo, co, random, block etc.) and the molecular weight of the polymer may also have an influence on morphology, in addition to the effects rendered with regard to item b.
  • the method comprises a continuous process for making a nonwoven fabric, where the fibers are continuously spun and directly dispersed on a carrier belt, preferably comprises making a spunbonded and/or meltblown nonwoven fabric.
  • the nonwoven formation procedure includes bonding of the nonwoven fibers.
  • Bonding may, for example, include calendaring and/or air-through bonding.
  • Using a thermal bonding procedure can be advantageous as it already acts as primary heat activation during the nonwoven formation procedure.
  • the additive comprises a hydrophobic molecule, preferably a hydrophobic molecule comprising a hydrocarbon chain of between 8-25 carbon atoms.
  • the additive comprises a fatty acid ester derived from C8-25, C10-20 or C14-18 saturated or unsaturated carboxylic acids. Examples comprise oleic acid, palmitic acid, myristic acid, myristoleic acid, oleic acid, limoleic acid, linoleic acid and arachidonic acid.
  • the fatty acid ester may be a triglyceride such as, for example, glycerol tristearate.
  • the melt additive may be present in an amount of greater 1.2 wt % or greater 2 wt % based on the total weight of the polymer component. In one embodiment, the melt additive may be present in an amount of smaller 8 wt % or smaller 6 wt % based on the total weight of the polymer component.
  • the component containing the additive may in one embodiment comprise higher additive contents. For example, contents of between 4-16 wt % are contemplated.
  • the invention further relates to a nonwoven fabric obtainable by the process of the invention.
  • Such fabric comprises polymer fibers where the melt additive is included in the polymer matrix, where the concentration of the melt additive is higher in a surface region than in a core region of the fibers and wherein the fibers comprise a rugged surface topography.
  • the surface comprises annexes such as fibrils, platelets or flakes that extend outwardly from the surface of the fibers.
  • Fibrils include shapes such as elongate projections and bumps.
  • the average radial elevation of the annexes from the surface may be in the range of 5 nm-50 ⁇ m, preferably 100 nm-30 ⁇ m and more preferably 500 nm-20 ⁇ m.
  • the nonwoven fabric comprises at least one spunbonded (S) layer which is obtained using the fibers from the additive-comprising melt of the polymer material.
  • S spunbonded
  • the nonwoven fabric comprises at least one meltblown (M) layer which is obtained using the fibers from the additive-comprising melt of the polymer material.
  • M meltblown
  • the nonwoven fabric is a spunmelt and preferably a layered SMS-type fabric wherein fibers of at least one of the S and/or M layers are obtained using the fibers from the additive-comprising melt of the polymer material.
  • the nonwoven fabric according to the invention may be used, for example, in a disposable hygiene article such as baby diapers, feminine hygiene products, wipes or adult incontinence products.
  • a disposable hygiene article such as baby diapers, feminine hygiene products, wipes or adult incontinence products.
  • the nonwoven can be utilized for both barrier performance application, e.g. barrier leg cuff in a diaper context, but also converted to act as a masking product, e.g. in a topsheet/core wrap application in feminine hygiene products.
  • Some steps of the present invention such as post production heat activation could be applied to selected zones of benefit to the target application.
  • hydrophobic melt additive more specifically PPM17000 High Load Hydrophobic, this refers to a masterbatch with an active component comprising 40 wt %.
  • LST-ST Low Surface Tension Strike Through
  • the surface tension of a liquid is determined by measuring the force exerted on a platinum Wilhelmy plate at the air-liquid interface.
  • a Kruss tensiometer K11 or equivalent is used. (Available by Kruss USA.) The test is operated in a laboratory environment at 23 ⁇ 2° C. and 50 ⁇ 5% relative humidity. The test liquid is placed into the container given by the manufacturer and the surface tension is recorded by the instrument and its software.
  • the low surface tension fluid strikethrough time test is used to determine the amount of time it takes a specified quantity of a low surface tension fluid, discharged at a prescribed rate, to fully penetrate a sample of a web (and other comparable barrier materials) which is placed on a reference absorbent pad. As a default, this is also called the 32 mN/m Low Surface Tension Fluid Strikethrough Test because of the surface tension of the test fluid and each test is done on two layers of the nonwoven sample simply laid on top of each other.
  • the reference absorbent pad is 5 plies of Ahlstrom grade 989 filter paper (10 cm ⁇ 10 cm) and the test fluid is a 32 mN/m low surface tension fluid.
  • the test is designed to characterize the low surface tension fluid strikethrough performance (in seconds) of webs intended to provide a barrier to low surface tension fluids, such as runny BM, for example.
  • Lister Strikethrough Tester The instrumentation is like described in EDANA ERT 153.0-02 section 6 with the following exception: the strike-through plate has a star-shaped orifice of 3 slots angled at 60 degrees with the narrow slots having a 10.0 mm length and a 1.2 mm slot width. This equipment is available from Lenzing Instruments (Austria) and from W. Fritz Metzger Corp (USA). The unit needs to be set up such that it does not time out after 100 seconds.
  • Reference Absorbent Pad Ahlstrom Grade 989 filter paper, in 10 cm ⁇ 10 cm areas, is used.
  • the average strikethrough time is 3.3+0.5 seconds for 5 plies of filter paper using the 32 mN/m test fluid and without the web sample.
  • the filter paper may be purchased from Empirical Manufacturing Company, Inc. (USA).
  • Test Fluid The 32 mN/m surface tension fluid is prepared with distilled water and 0.42+/ ⁇ 0.001 g/liter Triton-X 100. All fluids are kept at ambient conditions.
  • Electrode-Rinsing Liquid 0.9% sodium chloride (CAS 7647-14-5) aqueous solution (9 g NaCl per 1 L of distilled water) is used.
  • nonwoven web samples may be tested.
  • Cut the required number of nonwoven web specimens For web sampled off a roll, cut the samples into 10 cm by 10 cm sized square specimens. For web sampled off of a product, cut the samples into 15 by 15 mm square specimens. The fluid flows onto the nonwoven web specimen from the strike through plate. Touch the nonwoven web specimen only at the edge.
  • the nonwoven web specimen Place the nonwoven web specimen on top of the 5 plies of filter paper. Two plies of the nonwoven web specimen are used in this test method. If the nonwoven web sample is sided (i.e., has a different layer configuration based on which side is facing in a particular direction), the side facing the wearer (for an absorbent product) faces upwards in the test.
  • Spunbonded (S) single layer nonwoven fabrics were produced from 100-x wt % Ziegler-Natta polypropylene and x wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic) and thermally bonded.
  • the single S-layers had a weight of 20 g/m2.
  • the contents of the hydrophobic additive in Examples 1-4 are summarized in Table 1.
  • Three S single layer nonwovens were produced from 100% Ziegler-Natta polypropylene and thermally bonded.
  • the single S-layer had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated with an in-line Omega Drying oven at 90° C., 120° C. and 135° C., for Example 5, 6 and 7, respectively.
  • An S single layer nonwoven was produced from 100% Ziegler-Natta polypropylene and thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • the nonwoven was thermally treated with an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web.
  • An S single layer nonwoven was produced from 100% Ziegler-Natta polypropylene and thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • the nonwoven was thermally treated with an in-line Omega Drying oven at 120° C.
  • the through put had been decreased in the production of the material, resulting in a decreased line speed to increase the duration of the heat treatment.
  • the resulting heat treatment of Example 9 was 15% longer than that of Example 6.
  • An S single layer nonwoven was produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic) and thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • After the web making process of the nonwoven it was thermally treated with an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web, followed by heating in an Omega Drying oven at 120° C.
  • An S single layer nonwoven was produced from 90 wt % Ziegler-Natta polypropylene and 10 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic) and thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • the temperature of the calender thermally bonding the nonwoven was increased with +10° C.
  • An S single layer nonwoven was produced from 90% Ziegler-Natta polypropylene and 10 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic) and thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • the nonwoven was thermally treated with an in-line Omega Drying oven at 120° C.
  • the through put had been decreased in the production of the material, resulting in a decreased line speed to increase the duration of the in-line heat treatment.
  • the resulting heat treatment of Example 20 was 15% longer than that of Example 12 and comparable to the heat treatment of Example 6.
  • a Spunbond single layer fabric was produced with bicomponent core/sheath configuration, consisting of 70 wt % core and 30 wt % sheath.
  • the core comprised 100% Ziegler-Natta polypropylene.
  • the sheath comprised 67 wt % Ziegler-Natta polypropylene and 33 wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic).
  • PPM17000 High Load Hydrophobic The nonwoven was thermally bonded.
  • the single S-layer had a weight of 20 g/m2.
  • Spunbond single layer fabrics were produced with bicomponent core/sheath configuration, consisting of 70 wt % core and 30 wt %.
  • the core comprised 100 wt % Ziegler-Natta polypropylene.
  • the sheath comprised 100-X wt % Ziegler-Natta polypropylene and X wt % hydrophobic melt additive (PPM17000 High Load Hydrophobic).
  • PPM17000 High Load Hydrophobic hydrophobic melt additive
  • the nonwoven was thermally bonded.
  • the single S-layer had a weight of 20 g/m2. After the web making process of the nonwovens they were thermally treated by an in-line IR-heater set to 65% power at the center and 50% at the edge of the nonwoven web.
  • a spunbond single layer fabric was produced with bicomponent core/sheath configuration, consisting of 70 wt % core and 30 wt %.
  • the core comprised 100 wt % Ziegler-Natta polypropylene.
  • the sheath comprised 67 wt % propylene-based elastomer (consisting of approx. 15 wt % ethylene) and 33 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic).
  • PPM17000 High Load Hydrophobic hydrophobic melt additive
  • Example 21 to Example 25 reveals an increase in LST-ST from 28.47 seconds to 100.34 seconds when substituting Ziegler-Natta polypropylene in the sheath of the bicomponent fiber with a propylene-based elastomer in the sheath of the bicomponent fiber.
  • a spunbond single layer fabric was produced was produced from 80 wt % Ziegler-Natta polypropylene, 10 wt % of a hydrophobic melt additive (PPM17000 High Load Hydrophobic), and 10 wt % of a Calcium Carbonate masterbatch (Fiberlink 201S).
  • the fabric was thermally bonded.
  • the single S-layer had a weight of 20 g/m2. After the web making process of the nonwoven it was thermally treated by an in-line IR-heater set to 65% power at the center and 60% at the edge of the nonwoven web followed by in-line heating in an Omega Drying oven at 120° C.
  • a spunbond single layer fabric was produced was produced from 90 wt % Ziegler-Natta polypropylene, and 10 wt % of Calcium Carbonate masterbatch (Fiberlink 201S) and thermally bonded.
  • the single S-layer had a weight of 20 g/m2. After the web making process of the nonwoven it was thermally treated in an in-line Omega Drying oven at 120° C.
  • Example 26 and 27 An overview of Example 26 and 27 is provided in Table 11 below.
  • the LST-ST results reveal a LST ST of 5.51 seconds for Example 27, which shows that the presence of CaCO3 alone does not increase the LST-ST performance.
  • the LST-ST of Example 26 compared to Example 18, reveals that the presence of CaCO3 and the applied heat treatments of the IR-heater and Omega Drying oven increases the LST ST from 230.33 seconds to 679.98 seconds. When comparing the state of the art of Example 4 to Example 26, the performance increases from 13.59 seconds to 679.98 seconds.
  • Two SMMS-multilayered nonwoven fabrics were produced from Ziegler-Natta polypropylene.
  • the fabrics we added a hydrophobic additive (PPM17000 High Load Hydrophobic) to the various layers as described in Table 13.
  • PPM17000 High Load Hydrophobic a hydrophobic additive
  • Table 13 gives an overview on material layup, additive content and heat treatment.
  • Examples 28-29 were tested for Low Surface Tension Strike Through (LST-ST). The results are summarized in Table 14.
  • Three SS materials were produced with the spunbond fibers in both layers being bicomponent fibers of core/sheath configuration with a polyethylene sheath, accounting for 30 wt % of the total fiber, and polypropylene core, accounting for 70 wt % of the total fiber.
  • a hydrophobic additive (PM16310) was added in 17% to the bicomponent's PE sheath of both of S layers for Examples 30-32. After the web making process of Example 31-32 the fabrics were added a heat treatment with an in-line Omega Drying oven of 100° C. and 120° C. for Example 31 and Example 32, respectively.
  • Table 15 gives an overview on material layup, additive content and heat treatment.
  • Examples 30-32 were tested for Low Surface Tension Strike Through (LST-ST). The results are summarized in Table 16.

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